Mounting Assembly for a Face Shield

ABSTRACT

A face shield, such as a visor, mounts to a protective helmet using a mounting assembly. The mounting assembly has a base, a spacer assembly, and a pair of posts. The base is disposed on the interior of the helmet. The posts are connected to the base and extend outwardly through holes that are formed in the side of the helmet. The spacer assembly slides over the posts when the posts are inserted through the corresponding holes in the helmet, and frictionally engages the outer surfaces of the first and second posts such that the helmet is disposed between the base and the spacer assembly. The posts threadingly receive corresponding fasteners that attach the face shield to the helmet.

RELATED APPLICATIONS

This application is a continuation application of co-pending U.S.application Ser. No. 14/538,911, filed Nov. 12, 2014, which in turn, isa continuation application of U.S. application Ser. No. 13/038,427,filed Mar. 2, 2011, now issued as U.S. Pat. No. 8,899,867. Both the '911application and the '867 patent are incorporated herein by reference intheir entirety.

FIELD OF THE INVENTION

The present invention relates generally to face shields for protectiveheadgear, and particularly to mounting assemblies for removablyattaching a protective face shield to a headgear.

BACKGROUND

People wear protective headgear or helmets to help prevent headinjuries. In many cases, the headgear also includes a face shield, cage,or visor that attaches to the headgear to provide additional protectionfor a person's face and eyes. By way of example, ice hockey playersregularly wear a protective helmet with a face shield, cage, or visor toprotect their heads and faces from possible injuries due to impact withobjects such as the ice surface, other players, the boards, the puck,and sticks.

Conventionally, multiple mechanical fasteners, such as screws, are usedto attach the face shield to each side of the helmet. Each screw passesthrough corresponding holes formed in the face shield and helmet, andinto respective threaded nuts disposed on the inside of the helmet.However, attaching a face shield to a helmet using such conventionalhardware is problematic and frustrating. Specifically, face shields areusually manufactured from a high impact-resistant, clear plastic.Although they generally conform to the shape of the front of the helmetto surround the front of a player's face, the terminal ends of theshield tend to bias outwardly away from the exterior surface of thehelmet. This biasing force resists a user's efforts at initiallyattaching the face shield to the helmet. Additionally, when removing theface shield, the biasing force may “fling” the screws and/or othermounting assembly components away from the helmet if the user does notcarefully prevent this from happening.

SUMMARY

The present invention provides a mounting assembly for attachingprotective face shields to protective headgear. The helmet will protecta wearer's head from injuries that could occur due to contact with otherobjects. The face shield will help to protect the eyes and at least partof the wearer's face.

In one embodiment, the mounting assembly comprises a rectangular base,first and second posts, and a spacer assembly. The base has asubstantially planar surface and is configured to be disposed on theinterior of the helmet. The posts may be cylindrical and are connectedto the base. When installed, the posts extend outwardly from the basethrough corresponding holes formed in the side of the protective helmet.The posts are configured to threadingly receive one or more mechanicalfasteners that attach the face shield to the helmet. The spacerassembly, which may comprise one or more spacers, includes through holesthat allow the spacer assembly to slide over the extended posts. Thethrough holes are sized to fit tightly over the exterior surfaces of theextended posts such that the helmet is disposed between the planarsurface of the base and the spacer assembly. Such frictional engagementbetween the spacer assembly and the outer surfaces of the extended postsmaintains the base securely in place on the inside of the helmet duringthe installation and removal of the face shield.

The face shield, which may be a visor, for example, includes slots thatalign with the holes in the spacer assembly and the posts. Mechanicalfasteners, such as screws, extend through the slots in the face shieldand thread into the posts to secure the face shield to the helmet. Insome embodiments, the spacer assembly may include a raised ridge. Theridge is sized and shaped to fit within the slots in the shield. Theslots allow the ridge to move freely forward and backward along theslot, and thus, helps the user to install the face shield.

Of course, those skilled in the art will appreciate that the presentinvention is not limited to the above contexts or examples, and willrecognize additional features and advantages upon reading the followingdetailed description and upon viewing the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a protective face shield attached toprotective headgear according to one embodiment of the presentinvention.

FIG. 2 is an exploded view of the mounting assembly according to oneembodiment of the present invention.

FIGS. 3A-3C are plan views illustrating the mounting assembly componentsaccording to one or more embodiments of the present invention.

FIG. 4 is a sectional view illustrating the mounting assembly attachingthe face shield to the protective headgear according to one embodimentof the present invention.

FIG. 5A is a sectional view illustrating a spacer and post according toone embodiment of the present invention.

FIG. 5B is a sectional view illustrating a spacer and post according toanother embodiment of the present invention.

FIG. 6 is a perspective view illustrating a spacer assembly component ofthe mounting assembly configured according to one embodiment of thepresent invention.

FIG. 7 is an exploded view illustrating the mounting assembly attachinga face shield to protective headgear according to another embodiment ofthe present invention.

FIG. 8 is an exploded-sectional view illustrating how the mountingassembly attaches a face shield to protective headgear according to yetanother embodiment of the present invention.

DETAILED DESCRIPTION

The present invention provides a mounting assembly for attachingprotective face shields to protective headgear. The helmet will protecta wearer's head from injuries that could occur due to contact with otherobjects, while the face shield will help protect the eyes and at leastpart of the wearer's face. Some suitable examples of protective helmetshaving face shields include, but are not limited to, helmets used byfire, police, and/or other rescue personnel, as well as those worn byconstruction personnel, and sports figures participating in a sport thatrequires the use of helmets.

As stated previously, conventional face shields attach to protectivehelmets using multiple screws. Each screw extends through the faceshield and the helmet, and anchors into a corresponding T-nut positionedwithin the interior of the helmet. Although they secure the face shieldto the helmet, conventional components are small and difficult tomanipulate simultaneously with the helmet and the face shield. Further,whomever installs the face shield must maintain a constant pressure orforce on multiple components (e.g., the helmet, shield, T-nut, screw)during the installation process until the screw initially engages thethreads on the corresponding T-nut. The user must also maintain asimilar pressure on these components during the removal process toprevent the “biased” shield from flinging the screws and/or othercomponents across a room.

Thus, conventional methods of attachment are problematic andfrustrating, and are prone to the loss of the hardware needed to securethe face shield to the helmet. The present invention, however, obviatesthese problems by providing a mounting assembly that releasably securesthe face shield to the helmet. The mounting assembly comprises componentparts that are easier to manipulate than are the individual fasteners ofthe prior art. This negates the need for a user installing or removingthe face shield to simultaneously apply a continual pressure or force tomultiple components. Thus, with the mounting assembly of the presentinvention, it is easier for the user to hold and align both the faceshield and the helmet while attaching and removing the face shieldto/from the helmet.

Turning now to the drawings, FIG. 1 is a perspective view illustrating aprotective headgear of the type typically used by players in the sportof ice hockey. Those skilled in the art will readily appreciate that theuse of an ice hockey helmet 10 is illustrative only. The presentinvention may, in fact, be utilized for releasably securing protectiveface shields to other types of protective headgear.

As seen in FIG. 1, the protective headgear 10 comprises a helmet 12 anda face shield 16. The helmet 12 and the face shield 16 may comprise anyknown helmet and/or face shield known in the art, and are generallymanufactured by companies such as BAUER, CCM, EASTON, NIKE, ITECH,JOFFA, and CASCADE. As described in more detail later, a mountingassembly 30 configured according to one embodiment of the presentinvention attaches one end of the face shield 16 to the a first side ofhelmet 12. Although not specifically seen in FIG. 1, another mountingassembly 30 is present on the opposite side of helmet 12 to attach theother end of the face shield 16 to the other side of helmet 12.

Helmet 12 is typically constructed from a high impact-resistant plastic,and includes a specially formulated protective foam 14 affixed to theinterior. Generally, the foam 14 covers most or all of the interior ofhelmet 12, and is able to sufficiently absorb a kinetic impact toprotect the wearer to reduce the chance of concussion-related injuries.Some suitable types of foam 16 include, but are not limited to, ExpandedPolypropylene (EPP) foam and Fused Expanded Polypropylene (FXPP) foam.

The face shield 16 is arcuately shaped to generally conform to the shapeof the front of helmet 12 and the player's face. The face shield 16 istransparent and attaches to the helmet 12 at each lateral side using amounting assembly 30 configured according to the present invention. Likehelmet 12, the face shield 16 is manufactured from a highimpact-resistant plastic to specifically protect the player's eyes andat least a portion of the player's face from being injured by objectssuch as the puck, sticks, the ice surface, the boards, and the bodies ofthe other players.

There are different types of protective face shields 16 suitable for usewith the present invention. As seen in FIG. 1, for example, the faceshield 16 comprises a type of protective shield known as a “visor” or“half-shield.” The term “visor” is typically used to describe aprotective shield that covers and protects only the upper part of theplayer's face while leaving the lower part of the player's face open anduncovered. Another type of face shield suitable for use with the presentinvention, however, is a “full face shield.” The term “full face shield”is typically used to describe a transparent protective shield thatcovers most or all of the player's entire face. Similarly, a “cage” issometimes used as a protective face shield. A “cage” is a term used todescribe a metallic mesh formed as a grid that attaches to the front andsides of the helmet to cover and protects a person's entire face.

Regardless of the specific type of protective face shield, however, theterm “face shield” is used herein to generically refer to all threetypes of protective face shields—the “visor,” the “full face shield,”and the “cage.” Thus, although the presently illustrated embodimentsshow only a visor, those skilled in the art should appreciate that thisis for illustrative purposes only. The mounting assembly 30 of thepresent invention may be used to mount a visor, a full face shield, or acage to helmet 12.

FIG. 2 is an exploded view illustrating a mounting assembly 30configured according to one embodiment of the present invention and howit mounts the face shield 16 to helmet 12. As seen in FIG. 2, themounting assembly 30 comprises a substantially rectangular base 32 and apair of cylindrical posts 34 affixed to, and extending outwardly fromthe base 32. Each post 34 is approximately the same size and is includesa first threaded interior receptacle 36. The base 32 and the posts 34may be manufactured separately and fixedly attached to each other, orcast or molded as a unitary piece. Further, base 32 may be manufacturedfrom any material known in the art. Suitable materials include, but arenot limited to, any kind of metal or metal alloy and highimpact-resistant plastics.

The mounting assembly 30 further comprises a spacer assembly comprisingfirst and second spacers 38. As seen in FIG. 2, the first and secondspacers 38 are two independent and distinct objects; however, as seen inlater embodiments, this is not required. Each spacer 38 is disposed onthe exterior of the helmet 12, and includes a through hole 40 extendingthrough the spacer 38. The holes 40 are sized and shaped to conform tothe exterior surfaces of the posts 34. Specifically, the posts 34 extendoutwardly from the base 32 through holes 20 in the sides of helmet 12and into the through holes 40 of spacers 38. The posts 34 will notextend entirely through the holes 40 to contact the face shield 16. Theposts 34 will only extend far enough into the holes 40 such that theterminal ends of posts 34 are substantially flush with, or slightlybelow, the surface of the spacers 38. When installed, the spacerassembly frictionally engages the outer surfaces of the first and secondposts 34 such that the helmet 12 is disposed between the base 32 and thespacers 38.

In some embodiments, one or both of the spacers 38 also include a raisedridge R. The ridges R are formed on the surface, and are sized to seatwithin the horizontally-oriented slots 18 of face shield 16. The slots18 may be long enough to allow for some lateral movement (i.e., forwardand rearward movement) of the face shield 16 to facilitate the useraligning the shield 16 during the installation of the shield 16. Onceinstalled, the ridges R prevent the inadvertent rotation or movement ofthe face shield 16 due to factors such as the high-impact forces and/ortorque associated with a violent collision with another person orobject.

The mounting assembly 30 also comprises a pair of mechanical fasteners42 to attach the face shield 16 to the helmet 12. Generally, as seen inthe figures, the mechanical fasteners 42 comprise first and secondscrews; however, this is not required. The mechanical fasteners 42 maycomprise any mechanical fastener known in the art. In use, the fasteners42 extend through corresponding slots 18 formed in the face shield 16and threadingly engage the corresponding interior receptacles 36. Whenattached to the posts 34, fasteners 42 sufficiently secure the faceshield 16 to helmet 12.

The dimensions of the mounting assembly 30 components may be anydimensions needed or desired. However, in one embodiment, the dimensionsand structure of the protective face shield 16 and helmet 12 largelydefine the dimensions of the mounting assembly 30 components. Forexample, the mounting assembly 30 seen in FIGS. 3A-3C is for ice hockeyhelmets. In such embodiments, the base 32 (see FIG. 3A) has a lengthb_(L) of approximately 1 inch, a width b_(w) of about 0.5 inches, and aheight b_(H) of about 0.06 inches. Each post 34 has a height p_(H) ofapproximately 0.44 inches measured from the surface of the base 32, andhas an outer diameter p_(D) of approximately 0.21 inches. Each post 34is further positioned on the surface of the base 32 such that theirrespective center points p₁, p₂ are separated by a distance d_(CP) ofapproximately 0.54 inches apart. Additionally, the posts 34 are locatedon the base 32 such that each center point p₁, p₂ is locatedapproximately a first distance d_(S1) of about 0.23 inches from acorresponding short side of the base 32, and a second distance d_(S2) ofabout 0.25 inches from a corresponding long side of the base 32.

An exemplary spacer 38 is seen in FIG. 3B. Each spacer 38 has athickness of about 0.275 inches. The inner circumference C_(IN) of thehole 40 is about 0.21 inches, and the outer circumference C_(EXT) ofspacer 38 is about 0.5 inches. In embodiments where the spacer 38 has aridge R (FIG. 3C). The ridge R is raised about 0.06 inches from thesurface of the spacer 38. Regardless of the embodiment, the spacers 38may be constructed of any known material; however, in at least oneembodiment, the spacers 38 are manufactured from DELRIN.

FIG. 4 is a sectional view illustrating the face shield 16 mounted tothe helmet 12. For clarification, each component part of the mountingassembly 30 retains its previous reference number. However, FIG. 4indicates separate ones of the same component using the letters “a” and“b.” Thus, the first and second posts 34 are indicated as first andsecond posts 34 a, 34 b, respectively.

As seen in FIG. 4, the posts 34 a, 34 b are fixedly attached to the base32 and extend outwardly from base 32. Posts 34 extend outwardly frombase 32, through the holes 20 formed in helmet 12, and into the throughholes 40 of spacers 38 a, 38 b, respectively. The spacers 38 ensure thatthe helmet 12 remains disposed between the base 32 and the spacers 38 a,38 b, respectively. The fasteners 42 a, 42 b extend through the slots 18formed in the face shield 16, and into the corresponding threadedreceptacles 36 of posts 34 a, 34 b. Each of the opposing surfaces ofbase 32 is substantially planar and has a surface area that is generallygreater than that of a T-nut. Thus, base 32 has a first surface on whichthe user may apply a force F during the installation and/or removal ofthe shield 16 to maintain the opposing second surface of base 32 againstthe interior surface of helmet 12.

As previously stated, one of the problems with conventional visorattachment mechanisms is that they are difficult to handle andmanipulate while installing and removing the face shield 16. This ispartially because the face shield 16 has a tendency to bias away fromthe helmet, which can cause the screws and the other small attachmentcomponents to become lost. With the present invention, however, thecomponents of the mounting assembly 30 remain substantially in-place andconnected to the helmet 12 during the installation and removalprocesses. This eases the processes for the people who maintain suchequipment, and greatly reduces the chance of a component being “flung”across a room and lost. Additionally, since the components remainattached to the helmet 12 once installation of the mounting assembly 30is complete, the person removing the face shield 12 to utilize his orher hands for other tasks.

FIGS. 5A-5B are sectional views illustrating how the present inventionmay accomplish this aspect according to different embodiments of thepresent invention. Specifically, the through hole 40 of each spacer 38is sized to frictionally engage the outer surfaces of the posts 34 whenthe posts 34 are inserted through the holes 20 in the side of helmet 12.To accomplish this, each post 34 is formed to have an outer diameter d₁.The through hole 40 of the corresponding spacer 38, however, may beformed to have a slightly different diameter. In one embodiment (FIG.5A), the hole 40 has an inner diameter d₂ that is substantially equalto, or slightly smaller than, the outer diameter d₁ of post 34. Thediameter d₂ should be such that there is a yielding resistance impartedto the user when placing the spacer 38 over the post 34. However, oncein place, the spacer 38 should not freely separate from the post withoutsome force being applied by the user to intentionally remove the spacer38.

In another embodiment, (FIG. 5B), the hole 40 is tapered. Specifically,the hole 40 is formed to have two slightly different diameters d₃, d₄.The first diameter d₃ is slightly larger than the outer diameter d₁ ofpost 34 to facilitate the user initially sliding the spacer 38 over thepost 34. However, the second diameter d₄ is slightly smaller than theouter diameter d₁ to ensure that the spacer 38 will not freely separatefrom the post 34 without the user intentionally applying a predeterminedamount of force to remove the spacer.

FIG. 6 illustrates another embodiment of the spacer assembly utilized inthe mounting assembly 30. In previous embodiments, the spacer assemblycomprised a pair of independent spacers 38, each having their own hole40 to receive corresponding posts 34. In this embodiment, however, thespacer assembly comprises an elongated, single, unitary spacer 38 havinga pair of spaced-apart holes 40. As stated previously, the through holes40 in spacers 38 are sized and shaped to yieldingly resist the user'sefforts at placing the spacer over the post 34. It also yieldinglyresists the user's efforts at removing the spacer 38 from post 34thereby preventing the spacer 38 from becoming freely detached from post34. Thus, once installed, the spacers 38 function to retain or “lock”the base 32 and the posts 34 to the helmet 12, thereby preventing themounting assembly 30 from inadvertently becoming detached from thehelmet 12. Although not specifically shown in FIG. 6, the spacer 38 mayalso include the ridges R sized to fit into slots 18.

FIG. 7 illustrates another embodiment of the mounting mechanism 30 inwhich the external surfaces 44 of posts 34 are threaded. The internalsurfaces of the holes 40 on spacers 38 are also correspondinglythreaded. It should be noted that while FIG. 7 shows both spacers 38having threaded holes 40, this is not required. One or both of the holes40 may be threaded as needed or desired. To attach the face shield 16,the user places the threaded posts 34 through the holes 20 in helmet 12.The user then threads one or both of the spacers 38 onto the threadedpost(s) 34. This will retain the spacer 38 on the post 34, even when theuser removes the face shield 16 from helmet 12.

FIG. 8 illustrates another embodiment wherein one or both of the posts34 are threaded to receive two different sets of mechanical fasteners.Particularly, as previously stated, each post 34 a, 34 b has a firstthreaded interior receptacle 36 a, 36 b to threadingly receive themechanical fasteners 42 a, 42 b that retain the face shield 16 to thehelmet 12. In addition to these receptacles, however, each post 34 a, 34b also includes a second threaded interior receptacle 46 a, 46 b formedin the opposing end of the post. The second threaded receptacles 46 a,46 b are threaded in the opposite direction of the first threadedreceptacles 36 a, 36 b, and are configured to receive correspondingfasteners 50 a, 50 b via a hole 48 a, 48 b formed in the base 32. Thefasteners 50 a, 50 b may be utilized to hold the protective foam 14against the interior surface of the helmet 12. It should be noted that,although FIG. 8 illustrates both posts 34 a, 34 b as comprising a secondthreaded receptacle 46, this is not required. Those skilled in the artwill readily appreciate that one or both of the posts 34 a, 34 b mayinclude both a second threaded receptacle 46.

The present invention may, of course, be carried out in other ways thanthose specifically set forth herein without departing from essentialcharacteristics of the invention. For example, the posts 34 seen in theembodiments are all cylindrically-shaped. However, the present inventionis not so limited. Those skilled in the art will appreciate that theposts 34 may be any shape and size desired. Therefore, the presentembodiments are to be considered in all respects as illustrative and notrestrictive, and all changes coming within the meaning and equivalencyrange of the appended claims are intended to be embraced therein.

What is claimed is:
 1. A mounting assembly for attaching a face shieldto a protective helmet, the assembly comprising: a base having a planarsurface; first and second posts connected to, and extending outwardlyfrom, the base, wherein the first and second posts are configured to beinserted through corresponding holes in the helmet; and a spacerassembly comprising first and second spacers, each of the first andsecond spacers having a through hole configured to receive acorresponding one of the first and second posts when the first andsecond posts are inserted through the corresponding holes in the helmet,with the through hole of the first spacer configured to threadinglyengage the first post.
 2. The mounting assembly of claim 1 wherein thethrough hole of the first spacer threadingly engages an exteriorthreaded surface of the first post.
 3. The mounting assembly of claim 1wherein the through holes of both the first and second spacers areconfigured to threadingly engage the first and second posts,respectively.
 4. The mounting assembly of claim 1 wherein terminal endsof the first and second posts are substantially flush with, or below, asurface of the spacer assembly when the first and second posts areinserted through the corresponding holes in the helmet, and through therespective first and second through holes of the first and secondspacers.
 5. The mounting assembly of claim 1 wherein the first postcomprises a first interior receptacle configured to receive a fastenerattaching the face shield to the helmet.
 6. The mounting assembly ofclaim 5 wherein the first post further comprises a second interiorreceptacle formed in an opposing end of the first post, and isconfigured to receive a fastener from within an interior of the helmet.7. The mounting assembly of claim 6 wherein threads formed in the firstinterior receptacle are in a direction that is opposite the threadsformed in the second interior receptacle.
 8. The mounting assembly ofclaim 5 wherein both of the first and second posts comprise respectivefirst and second interior receptacles configured to receivecorresponding fasteners attaching the face shield to the helmet.
 9. Aface shield assembly for mounting to a protective helmet, the assemblycomprising: a face shield; a mounting assembly configured to mount theface shield to the helmet, the assembly comprising: a base having aplanar surface; first and second posts connected to, and extendingoutwardly from, the base, wherein the first and second posts areconfigured to be inserted through corresponding holes in the helmet; anda spacer assembly comprising first and second spacers, each of the firstand second spacers having a through hole configured to receive acorresponding one of the first and second posts when the first andsecond posts are inserted through the corresponding holes in the helmet,with the through hole of the first spacer configured to threadinglyengage the first post.
 10. The face shield assembly of claim 9 whereinthe through hole of the first spacer threadingly engages an exteriorthreaded surface of the first post.
 11. The face shield assembly ofclaim 9 wherein the through holes of both the first and second spacersare configured to threadingly engage exterior threaded surfaces of thefirst and second posts, respectively.
 12. The face shield assembly ofclaim 9 wherein terminal ends of the first and second posts aresubstantially flush with, or below, a surface of the spacer assemblywhen the first and second posts are inserted through the correspondingholes in the helmet, and through the respective first and second throughholes of the first and second spacers.
 13. The face shield assembly ofclaim 9 wherein the first post comprises a first interior receptacleconfigured to receive a fastener attaching the face shield to thehelmet.
 14. The face shield assembly of claim 13 wherein the first postfurther comprises a second interior receptacle formed in an opposing endof the first post, and is configured to receive a fastener from withinan interior of the helmet.
 15. The face shield assembly of claim 14wherein threads formed in the first interior receptacle are in adirection that is opposite the threads formed in the second interiorreceptacle.
 16. The face shield assembly of claim 13 wherein both of thefirst and second posts comprise respective first and second interiorreceptacles configured to receive corresponding fasteners attaching theface shield to the helmet.
 17. A protective helmet comprising: amounting assembly configured to mount a face shield to the helmet, theassembly comprising: a base having a planar surface; first and secondposts connected to, and extending outwardly from, the base, wherein thefirst and second posts are configured to be inserted throughcorresponding holes in the helmet; and a spacer assembly comprisingfirst and second spacers, each of the first and second spacers having athrough hole configured to receive a corresponding one of the first andsecond posts when the first and second posts are inserted through thecorresponding holes in the helmet, with the through hole of the firstspacer configured to threadingly engage the first post.